Devices and methods for indicating power on a torch

ABSTRACT

Devices and methods for indicating power on a torch. In one example, a welding or plasma cutting torch includes an indicator coupled to the torch. The torch also includes control circuitry coupled to the indicator and configured to provide a first signal and a second signal to the indicator. The indicator is configured to receive the first signal when at least one of welding power and arc starting power from a power supply is available at the torch and to receive the second signal when the at least one of active welding power and the arc starting power from the power supply is not available at the torch.

BACKGROUND

The invention relates generally to welding and plasma cutting torchesand, more particularly, to devices and methods for indicating power on atorch.

Welding is a process that has become increasingly prevalent in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure that the supply of weldingconsumables (e.g., wire, shielding gas, etc.) is provided to the weld inan appropriate amount at the desired time. For example, metal inert gas(MIG) welding typically relies on a wire feeder to enable a welding wireto reach a welding torch. The wire is continuously fed during welding toprovide filler metal. A power source ensures that arc heating isavailable to melt the filler metal and the underlying base metal.

In welding applications, a welding power supply typically provideswelding power and/or arc starting power for welding. The welding powerand/or arc starting power is provided to the torch such that, whenactive, a welding arc may be formed by placing the torch in closeproximity to a workpiece. To determine if welding power and/or arcstarting power is currently available at the torch, the welding operatormay look at information displayed on the welding power supply or anotherwelding device. Unfortunately, the welding operator may not be closeenough to the welding device to look at the welding device and/or it maynot be possible for the welding operator to look at the welding device.Moreover, in plasma cutting applications, a plasma cutting operator maydesire to know if power is available at the plasma cutting torch and,similar to the welding operator, may not be close enough to the plasmacutting power supply and/or it may not be possible for the plasmacutting operator to look at the plasma cutting power supply.Accordingly, there is a need in the field for methods and/or devicesthat provide an operator with power availability information from awelding or plasma cutting power supply.

BRIEF DESCRIPTION

In one embodiment, a welding or plasma cutting torch includes anindicator coupled to the torch. The torch also includes controlcircuitry coupled to the indicator and configured to provide a firstsignal and a second signal to the indicator. The indicator is configuredto receive the first signal when at least one of welding power and arcstarting power from a power supply is available at the torch and toreceive the second signal when the at least one of the welding power andthe arc starting power from the power supply is not available at thetorch.

In another embodiment, a method for indicating that a welding torch isreceiving at least one of active welding power and arc starting powerfrom a welding power supply includes receiving a first signal at thewelding torch while the welding torch is receiving the at least one ofactive welding power and the arc starting power. The method alsoincludes receiving a second signal at the welding torch while thewelding torch is not receiving the at least one of active welding powerand the arc starting power. The first signal is configured to provide afirst indication that the welding torch is receiving the at least one ofactive welding power and the arc starting power and the second signal isconfigured to provide a second indication that the welding torch is notreceiving the at least one of active welding power and the arc startingpower.

In another embodiment, a welding or plasma cutting torch includes anindicator configured to indicate when at least one of welding power andarc starting power is available at the torch.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of an embodiment of a welding power supplyemploying a welding torch with a power indicator;

FIG. 2 is a side view of an embodiment of the welding torch of FIG. 1;

FIG. 3 is a schematic diagram of an embodiment of a welding systemhaving a welding torch with a power indicator;

FIG. 4 is a schematic diagram of another embodiment of a welding systemhaving a welding torch with a power indicator; and

FIG. 5 is a flow chart of an embodiment of a method for indicating thata welding torch is receiving active welding power from a welding powersupply.

DETAILED DESCRIPTION

Turning now to the drawings, FIG. 1 is a perspective view of anembodiment of a welding power supply 10 employing a welding torch with apower indicator. The welding power supply 10 includes a housing 12having a top panel 14, a side panel 16, and a front panel 18. The toppanel 14 may include a handle that facilitates transport of the weldingpower supply 10 from one location to another by an operator. The frontpanel 18 includes a control panel 20 adapted to allow an operator to setone or more parameters of the welding process, for example, via knobs 22(or buttons, touchscreens, etc.). The control panel 20 may also includeindicators that provide information to the operator (e.g., voltage,current, power availability, etc.).

In certain embodiments, the welding power supply 10 includes thefunctionality of a wire feeder (i.e., internal wire feeder). Suchembodiments may include a wire drive configured to receive controlsignals to drive a wire spool. The wire drive feeds wire for the weldingoperation. In other embodiments, a separate wire feeder may be used inconjunction with the welding power supply 10 (i.e., external wirefeeder). Such a separate wire feeder may also include a wire drive and awire spool.

A main electrical connector 24 is coupled to the welding power supply 10via the front panel 18. A cable 26 extends from the main connector 24 toa welding torch 28 configured to establish a welding arc during awelding operation. The welding torch 28 includes a trigger 30 thatinitiates a welding operation and causes welding wire to be supplied tothe welding operation by exposing welding wire when pressed.Furthermore, pressing the trigger 30 may cause a switch in the trigger30 to be actuated. In other embodiments, wire may be supplied to awelding operation using a spoolgun attached to a welding power supply.In such configurations, the spoolgun may include a trigger to supplywelding wire.

The welding torch 28 includes an indicator 32 coupled to a body of thewelding torch 28 and configured to indicate when welding power and/orarc starting power is available at the welding torch 28 (e.g., whether awelding arc may be formed while the trigger 30 is pressed). For example,the indicator 32 may indicate that welding power is available, that anarc starting power is available (e.g., a high frequency signal, a highvoltage signal, a high current signal, etc.), and so forth. Theindicator 32 may include any suitable type of indicator, such as anaudio indicator, a visual indicator, a tactile indicator, and so forth.Moreover, the indicator 32 may include any suitable indicating device,such as a display, a screen, a light-emitting diode (LED), a light, aspeaker, and/or a motor. For example, in certain embodiments, theindicator 32 may include a motor configured to provide tactile (e.g.,vibration) feedback to the operator. In some embodiments, the indicator32 may include a speaker configured to provide audible feedback (e.g.,sounds) to the operator. Moreover, in other embodiments, the indicator32 may include a display configured to provide visual (e.g., lights,pictures, illumination, flashing, etc.) feedback to the operator.

In certain embodiments, the indicator 32 may be configured to provide anindication when welding power and/or arc starting power is available atthe welding torch 28. For example, in embodiments in which the indicator32 is an LED, the LED may be on (e.g., illuminated) when welding powerand/or arc starting power is available at the welding torch 28.Accordingly, if the LED is off (e.g., not illuminated), welding powerand/or arc starting power is not available at the welding torch 28. Inother embodiments, the indicator 32 may be configured to provide anindication when welding power and/or arc starting power is not availableat the welding torch 28. For example, in embodiments in which theindicator 32 is an LED, the LED may be off when welding power and/or arcstarting power is available at the welding torch 28. Accordingly, if theLED is on, welding power and/or arc starting power is not available atthe welding torch 28. Alternatively, in certain embodiments, the weldingtorch 28 may include one or more LEDs to positively indicate both whenwelding power and/or arc starting power is available and when weldingpower and/or arc starting power is not available. For example, the LEDsmay illuminate a first color (e.g., green) when welding power and/or arcstarting power is available and illuminate a second color (e.g., red)when welding power and/or arc starting power is not available.

As may be appreciated, the indicator 32 may be configured to provide anindication in any suitable manner. Therefore, a welding operator usingthe welding torch 28 may receive an indication at the welding torch 28that provides the welding operator with information about theavailability of welding power and/or arc starting power at the weldingtorch 28. As may be appreciated, even though the welding torch 28 isillustrated, in other embodiment, a torch for plasma cutting, or a torchfor another type of welding-type application, may include the indicator32 for indicating that power is available at the torch.

A second cable 34 is attached to the welding power supply 10 through anaperture in the front panel 18 and terminates in a clamp 36 that isadapted to clamp to the workpiece during a welding operation to closethe circuit between the welding power supply 10, the welding torch 28,and the workpiece. During such an operation, the welding power supply 10is configured to receive primary power from a primary power supply, suchas a power source (e.g., the power grid, engine-generator, etc.), tocondition such incoming power, and to output a weld power outputappropriate for use in the welding operation. Further, in certainembodiments, the welding power supply 10 may be configured to receiveshielding gas, such as from a gas supply cylinder.

FIG. 2 is a side view of an embodiment of the welding torch 28 ofFIG. 1. The welding torch 28 includes a handle 38 for a welding operatorto hold while performing a weld. At a first end 40, the handle 38 iscoupled to the cable 26 where welding consumables are supplied to theweld. Welding consumables generally travel through the handle 38 andexit at a second end 42 opposite from the first end 40. The weldingtorch 28 includes a neck 44 extending out of the end 42. As such, theneck 44 is coupled between the handle 38 and a nozzle 46. As should benoted, when the trigger 30 is pressed or actuated, welding wire travelsthrough the cable 26, the handle 38, the neck 44, and the nozzle 46, sothat the welding wire extends out of an end 48 (i.e., torch tip) of thenozzle 46.

As illustrated, the handle 38 is secured to the neck 44 via fasteners 50and 52, and to the cable 26 via fasteners 54 and 56. The nozzle 46 isillustrated with a portion of the nozzle 46 removed to show welding wire58 extending out of a guide or contact tip 60 (or other guiding device).The guide tip 60 is used to guide the welding wire 58 out of the end 48of the welding torch 28. Although one type of welding torch 28 isillustrated, any suitable type of welding torch may include theindicator 32. For example, a welding torch having the indicator 32 maybe configured for shielded metal arc welding (SMAW), gas tungsten arcwelding (GTAW), gas metal arc welding (GMAW), and so forth.

FIG. 3 is a schematic diagram of an embodiment of a welding system 62having the welding torch 28 with the power indicator 32. The weldingsystem 62 includes a welding device 64 (e.g., a welding power supply, awire feeder, a pendant, etc.) configured to provide welding power to thewelding torch 28 via a welding power conductor 66. Specifically, thewelding device 64 (e.g., the welding power supply 10 of FIG. 1) includescontrol circuitry 68 configured to provide the welding power to thewelding torch 28 and/or to condition the welding power provided to thewelding torch 28. The control circuitry 68 is coupled to a conductor 70which provides a conductive pathway between the control circuitry 68 anda workpiece 72 to facilitate current flow for a welding operation.

The trigger 30 of the welding torch 28 includes a switch 74 thatswitches between an open position and a closed position based on whetherthe trigger 30 is actuated. Conductors 76 and 78 are coupled between theswitch 74 of the trigger 30 and the control circuitry 68 of the weldingdevice 64. The switch 74 controls whether there is conductivity betweenthe conductors 76 and 78. For example, when the switch 74 is open (e.g.,the trigger 30 is not actuated or pressed) there is no conductivitybetween the conductors 76 and 78. In contrast, when the switch 74 isclosed (e.g., the trigger 30 is actuated or pressed) there isconductivity between the conductors 76 and 78. As may be appreciated,the control circuitry 68 of the welding device 64 may be configured todetect whether the switch 74 is open or closed. Accordingly, the controlcircuitry 68 may be used to determine whether the trigger 30 is actuatedor pressed.

The welding torch 28 includes control circuitry 80 coupled to theindicator 32 and configured to provide one or more signals to theindicator 32. In the illustrated embodiment, the conductors 82 and 84are coupled between the control circuitry 68 of the welding device 64and the control circuitry 80 of the welding torch 28. In certainembodiments, the control circuitry 80 may provide one or more signals tothe indicator 32 based on a voltage difference between the conductors 82and 84. For example, the control circuitry 80 may receive a first signal(e.g., voltage) based on a first voltage difference between theconductors 82 and 84. Moreover, the control circuitry 80 may receive asecond signal (e.g., voltage) based on a second voltage differencebetween the conductors 82 and 84. In some embodiments, the first signalmay indicate that welding power and/or arc starting power from thewelding device 64 is available at the welding torch 28. Furthermore, thesecond signal may indicate that welding power and/or arc starting powerfrom the welding device 64 is not available at the welding torch 28. Thecontrol circuitry 80 may provide the first and second signals to theindicator 32 to facilitate the indicator 32 providing information aboutthe availability of power to the operator of the welding torch 28.

The control circuitry 68 of the welding device 64 may use variouslogical methods to determine when welding power is available at thewelding torch 28. For example, the control circuitry 68 may indicatethat welding power and/or arc starting power is available at the weldingtorch 28 only when the trigger 30 is actuated. Accordingly, if theswitch 74 is open, the control circuitry 68 may indicate acrossconductors 82 and 84 that welding power and/or arc starting power is notavailable at the welding torch 28. Furthermore, if the switch 74 isclosed and welding power and/or arc starting power is available acrossconductors 66 and 70, the control circuitry 68 may indicate acrossconductors 82 and 84 that welding power and/or arc starting power isavailable at the welding torch 28.

In certain embodiments, the control circuitry 68 of the welding device64 and/or the control circuitry 80 of the welding torch 28 may have oneor more monitors for detecting the availability of welding power and/orarc starting power. For example, the control circuitry 68 and/or thecontrol circuitry 80 may have a voltage monitor, a current monitor, andso forth. In some embodiments, the control circuitry 68 and/or thecontrol circuitry 80 may detect a voltage across the conductors 66 and70 (e.g., while welding is not occurring). In other embodiments, thecontrol circuitry 68 and/or the control circuitry 80 may detect acurrent between the conductors 66 and 70 (e.g., while welding isoccurring). The presence of a voltage or a current across the conductors66 and 70 may be used to indicate that welding power and/or arc startingpower is available at the welding torch 28.

The control circuitry 80 of the welding torch 28 may be configured topower the indicator 32 and/or provide suitable signals to drive theindicator 32 to provide power indications to the welding operator.Accordingly, the welding operator may be able to determine whether poweris available at the welding torch 28 simply by looking at the indicator32 on the welding torch 28. As may be appreciated, the conductors 66,70, 76, 78, 82, and 84 may be combined into a single cable and/or may bepart of multiple cables. For example, in certain embodiments, theconductors 76, 78, 82, and 84 may be part of a control cable (e.g.,14-pin cable).

FIG. 4 is a schematic diagram of another embodiment of a welding system86 having the welding torch 28 with the power indicator 32. In theillustrated embodiment, the welding device 64 includes a transceiver 88configured to send and/or receive wireless signals 90. The transceiver88 of the welding device 64 may be configured to communicate with atransceiver 92 of the welding torch 28 via wireless signals 94 sent toand/or received from the transceiver 92. Accordingly, the transceiver 92of the welding torch 28 may receive signals from the transceiver 88 ofthe welding device 64. The received signals may indicate whether weldingpower and/or arc starting power is available at the welding torch 28.Furthermore, the transceiver 92 of the welding torch 28 may providesignals to the transceiver 88 of the welding device 64 indicatingwhether the switch 74 of the trigger 30 is open or closed. Moreover, abattery 96 is coupled to the control circuitry 80 to provide power tothe control circuitry 80, the transceiver 92, and/or the indicator 32.In such a configuration, conductors 76, 78, 82, and 84 may not beincluded, thereby reducing the number of conductors that extend betweenthe welding device 64 and the welding torch 28.

FIG. 5 is a flow chart of an embodiment of a method 98 for indicatingthat the welding torch 28 is receiving active welding power and/or arcstarting power from the welding power supply 10. In the method 98, thecontrol circuitry 80 of the welding torch 28 receives a first signalwhile the welding torch 28 is receiving welding power and/or arcstarting power (block 100). For example, the control circuitry 80 mayreceive a signal represented by a voltage difference between conductors82 and 84. As another example, the control circuitry 80 may receive adigital signal wirelessly via the transceiver 92 indicating that thewelding torch 28 is receiving welding power and/or arc starting power.The control circuitry 80 provides a first indication to the indicator 32that the welding torch 28 is receiving welding power and/or arc startingpower based on the first signal (block 102). For example, the controlcircuitry 80 may power an LED, provide image data to a display, removepower from an LED, remove image data from a display, provide audio datato a speaker, power a motor, remove power from a motor, and so forth,based on the first signal.

The control circuitry 80 of the welding torch 28 receives a secondsignal while the welding torch 28 is not receiving welding power and/orarc starting power (block 104). For example, the control circuitry 80may receive a signal represented by a voltage difference betweenconductors 82 and 84. As another example, the control circuitry 80 mayreceive a digital signal wirelessly via the transceiver 92 indicatingthat the welding torch 28 is not receiving welding power and/or arcstarting power. The control circuitry 80 provides a second indication tothe indicator 32 that the welding torch 28 is not receiving weldingpower and/or arc starting power based on the second signal (block 106).For example, the control circuitry 80 may power an LED, provide imagedata to a display, remove power from an LED, remove image data from adisplay, provide audio data to a speaker, power a motor, remove powerfrom a motor, and so forth, based on the second signal.

The devices and methods described herein may be used to provide anindication to a welding or plasma cutting operator that power isavailable at the torch. The indication is provided from the torch sothat the operator may receive the indication regardless of theirlocation (e.g., even when the operator is not close to the weldingdevice that may be providing power). Moreover, the operator may receivethe indication prior to and/or during the welding or plasma cuttingoperation.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A welding or plasma cutting torch,comprising: an indicator coupled to a body of the torch; and controlcircuitry coupled to the indicator and configured to provide a firstsignal and a second signal to the indicator; wherein the indicator isconfigured to receive the first signal when at least one of weldingpower and arc starting power from a power supply is available at thetorch, the indicator is configured to receive the second signal when theat least one of the welding power and the arc starting power from thepower supply is not available at the torch, the first signal comprises avoltage signal while welding or cutting is not occurring, and the firstsignal comprises a current signal while welding or cutting is occurring.2. The torch of claim 1, wherein the indicator comprises a visualindicator.
 3. The torch of claim 2, wherein the visual indicatorcomprises a light-emitting diode.
 4. The torch of claim 2, wherein thevisual indicator comprises a display.
 5. The torch of claim 1, whereinthe indicator comprises an audio indicator.
 6. The torch of claim 1,wherein the control circuitry comprises a battery for providing power tothe control circuitry and to the indicator.
 7. The torch of claim 1,wherein the control circuitry comprises a wireless receiver forwirelessly communicating with the power supply.
 8. The torch of claim 1,wherein the first signal comprises a first voltage and the second signalcomprises a second voltage while welding or cutting is not occurring. 9.The torch of claim 1, wherein the first signal and the second signal areprovided by a device in a welding system.
 10. The torch of claim 1,comprising a torch trigger configured to be actuated during a welding orplasma cutting operation.
 11. The torch of claim 10, wherein theindicator is configured to receive the first signal while the torchtrigger is being actuated.
 12. A method for indicating that a weldingtorch is receiving at least one of active welding power and arc startingpower from a welding power supply, comprising: receiving a first signalat the welding torch while the welding torch is receiving the at leastone of the active welding power and the arc starting power; providing afirst indication that the welding torch is receiving the at least one ofthe active welding power and the arc starting power based at leastpartly on the first signal; receiving a second signal at the weldingtorch while the welding torch is not receiving the at least one of theactive welding power and the arc starting power; and providing a secondindication that the welding torch is not receiving the at least one ofthe active welding power and the arc starting power based at leastpartly on the second signal.
 13. The method of claim 12, whereinreceiving the first signal at the welding torch comprises receiving afirst voltage at the welding torch, and receiving the second signal atthe welding torch comprises receiving a second voltage at the weldingtorch.
 14. The method of claim 12, wherein receiving the first signal atthe welding torch and receiving the second signal at the welding torcheach comprise receiving wireless data from a device in a welding system.15. The method of claim 12, wherein providing the first indication thatthe welding torch is receiving the at least one of the active weldingpower and the arc starting power comprises powering a visual indicator,and providing the second indication that the welding torch is notreceiving the at least one of the active welding power and the arcstarting power comprises removing power from the visual indicator. 16.The method of claim 12, wherein providing the first indication that thewelding torch is receiving the at least one of the active welding powerand the arc starting power comprises providing a first image on adisplay of the welding torch, and providing the second indication thatthe welding torch is not receiving the at least one of the activewelding power and the arc starting power comprises providing a secondimage on the display of the welding torch.
 17. A welding or plasmacutting torch comprising: an indicator configured to indicate when atleast one of welding power and arc starting power is available at thetorch; and a battery configured to power the indicator.
 18. The torch ofclaim 17, comprising a wireless receiver configured to receive anindication that the at least one of the welding power and the arcstarting power is available at the torch.
 19. The torch of claim 17,wherein the indicator comprises a light-emitting diode (LED) that isconfigured to be illuminated when the at least one of the welding powerand the arc starting power is available at the torch.
 20. The torch ofclaim 17, comprising control circuitry configured to detect availabilityof the at least one of welding power and arc starting power viadetection of a signal across a first conductor coupled to the torch anda second conductor coupled to a workpiece.